JP5425226B2 - Rotating electric machine and manufacturing method thereof - Google Patents

Description

  The present invention relates to a rotating electrical machine having a stator in which a predetermined number of stator divided bodies each having an electric wire wound around a stator piece are joined in an annular shape, and a method for manufacturing the same.

  In conventional rotating electrical machines, a ground insulating layer is provided by an insulator formed integrally with a stator piece made of laminated electromagnetic steel sheets, and enamel-coated electric wires are wound on this ground insulating layer to create a stator split body. A predetermined number of these are joined to form an annular stator. (For example, refer to Patent Document 1). Further, since the windings of the adjacent stator divided bodies have different phases, the insulating sheet inserted between the adjacent windings and the gap surrounded by the insulating sheet, the windings, and the insulator are filled. An insulating layer between the phases is formed in the resin portion. (For example, refer to Patent Document 2).

JP 2000-333388 A JP 2000-333399 A

  In a conventional stator of a rotating electric machine, insulation between adjacent windings of different phases is ensured by an insulating sheet and a resin part. However, there is a problem that the space factor of the winding is limited.

  Also, if the thickness of the insulating sheet and the resin part is reduced in order to increase the space factor of the winding, the influence of weak points on the insulation of the resin part, such as voids and peeling, becomes significant, and surge There was a problem that dielectric breakdown occurred at high voltage.

  The present invention has been made to solve the above-described problems, and provides a high-efficiency rotating electrical machine that improves the space factor of the winding while maintaining the reliability of insulation. Objective.

In the rotating electrical machine according to the present invention, a predetermined number of stator divided bodies each having a winding formed by winding an electric wire on a stator piece divided in the circumferential direction in units of pole teeth and laminated with electromagnetic steel sheets. an electric motor having a stator which is joined to the annular, among multiple stator divided body, the windings of the stator divided bodies adjacent faces at the respective outermost layers the wire section, wire, An electric wire that has only the first insulating coating for the inner wires other than the outermost layer, has the first insulating coating in the outermost layer portion, and further forms at least one of the outermost electric wire portions. predetermined portion of the over the first insulating coating comprises a second insulating coating, the second insulating coating, uneven surface and a gap covering the face of the opposite side, and facing the adjacent wire There is no close contact.

Moreover, it is a manufacturing method of a rotating electrical machine, the step of winding an electric wire having a first insulation coating around a winding groove of a stator piece covered with an insulator, an outermost layer electric wire of the electric wire having the first insulation coating Forming a stator segment by forming a second insulation coating on the part by powder coating or electrodeposition coating, forming a stator by joining a predetermined number of stator segments in an annular shape, And a step of inserting and assembling the rotor into the stator.
Also, a step of forming a second insulating coating by powder coating or electrodeposition coating on a predetermined portion of the electric wire having the first insulating coating, and winding of the stator piece covered with the insulator on the formed electric wire Winding the groove so that a predetermined part covers the outermost layer of the winding to form a stator divided body, joining a predetermined number of stator divided bodies in a ring shape to form a stator, and the stator And a step of inserting and assembling the rotor.

  The present invention can provide a high-efficiency rotating electric machine that improves the space factor of the stator windings while maintaining the insulation reliability.

It is the perspective view which decomposed | disassembled some rotary electric machines of Embodiment 1 of this invention. It is the perspective view which notched a part of stator of the rotary electric machine of Embodiment 1 of this invention. It is a perspective view for demonstrating the structure of the stator division body of Embodiment 1 of this invention. It is sectional drawing which shows the cross section S of FIG.3 (c). It is a schematic diagram for demonstrating the method of providing a 2nd insulation coating to the electric wire of Embodiment 1 of this invention. It is the front view which wound the electric wire provided with the 2nd insulation coating of Embodiment 1 of this invention around the winding frame. It is sectional drawing which shows the state of the joining of the stator division body adjacent to each other of Embodiment 1 of this invention. It is sectional drawing which shows the cross section AA of FIG. It is sectional drawing which shows the state of the joining of the stator division body adjacent to each other of Embodiment 2 of this invention. It is sectional drawing which shows the state of the joining of the mutually adjacent stator division body of Embodiment 3 of this invention. It is explanatory drawing for demonstrating the influence of the void ratio of the 2nd insulation coating which concerns on Embodiment 1 of this invention. It is sectional drawing which shows the state of the joining of the stator division body adjacent to each other of Embodiment 4 of this invention.

Embodiment 1 FIG.
FIG. 1 shows a rotating electrical machine 1 according to Embodiment 1 for carrying out the present invention. In FIG. 1, the stator 2 is held by a housing 4 so as to surround the rotor 3. The rotor 2 is configured integrally with a rotating shaft 5, and the rotating shaft 5 is rotatably held by a bearing 6.

  FIG. 2 shows a plurality of stator divided bodies 11 each having a winding 10 formed by winding an electric wire 9 on a stator piece 7 divided in the circumferential direction in units of pole teeth and laminated with electromagnetic steel plates. It is a perspective view which shows the stator 2 joined to several ring shape, and is notched so that the internal structure of the stator division | segmentation body 11 may be understood. FIG. 3 is a perspective view for explaining the configuration of the stator divided body 11. As shown in FIG. 3 (a), the stator divided body 11 is formed by covering the stator piece 7 punched out in a substantially T shape after laminating the electromagnetic steel sheets with an insulator 13 as shown in FIG. 3 (b). A winding groove 12 that is insulated from the stator piece 7 is formed, and as shown in FIG. 3C, a winding 10 is formed by winding an electric wire 9 around the winding groove 12. The insulator 13 ensures the insulation between the stator piece 7 and the winding 10 and plays a role in preventing damage to the electric wire 9 wound with tension. In general, since the stator piece 7 is at ground potential, the insulator 13 serves to insulate the winding 10 from the ground.

  FIG. 4 shows a cross-sectional view of the cross section S of FIG. 3C viewed from the direction of the arrow in the figure, and the electric wire 9 is a coating obtained by applying a first insulating coating 8b, for example, enamel coating, to the conducting wire 8a. It is an electric wire and is wound sequentially from the central axis side of the stator piece 7. Outermost layer electric wire portion 9a located in the outermost layer of winding 10 of stator divided body 11 faces winding 10 of another adjacent stator divided body 11 (not shown). The outermost layer electric wire portion 9a is provided with a second insulating coating 14 in addition to the first insulating coating 8b.

  FIG. 5 is a schematic diagram for explaining a method of providing the second insulating coating 14 on the electric wire according to the first embodiment of the present invention. 5A shows a cross section BB of FIG. 5B, and FIG. 5B shows a cross section AA of FIG.

  As shown in FIG. 5, the second insulating coating 14 is made of an insulating material mainly composed of a resin, such as epoxy, polyimide, polyamide, polyester, PPS (polyphenylene sulfide), etc. An insulating film mainly composed of a thermoplastic resin is applied from above the first insulating coating 8b of the predetermined portion 9aa of the electric wire 9 which is the outermost layer electric wire portion 9a before winding, so that an arbitrary thickness can be easily obtained. It can be made variable. Moreover, by using powder coating, electrodeposition coating, or the like, a high-quality insulating film having almost no voids can be obtained as compared with injection molding or resin filling in the gap between already wound wires. In addition, since the formation of the second insulating coating 14 on the outermost layer electric wire portion 9a is performed in advance on the predetermined portion 9aa of the electric wire 9 to be wound, the coating treatment can be performed in an optimum environment, and a stable film quality can be obtained. can get.

FIG. 11 is an explanatory diagram for explaining the influence of the void ratio of the second insulating coating 14 according to the first embodiment of the present invention, and the withstand voltage V ₀ of the second insulating coating 14 when there is no void. The ratio of the withstand voltage V _α when the void content α is 1%, 2%, 3%, and 4%, respectively, is shown. From the figure, it can be seen that when the void content α is larger than 2%, the withstand voltage suddenly decreases. That is, by suppressing the void content α to 2% or less, it is possible to obtain a withstand voltage corresponding to the case where there is no void.

  As shown in FIG. 6, the outermost layer electric wire portion 9 a on which the second insulating coating 14 is formed and the unprocessed electric wire portion 9 c having only the first insulating coating 8 b are continuously connected to one electric wire 9. It is supplied to the winding process in a state of being wound around the winding frame 16, and is wound around the winding groove 12 of the stator piece 7 covered with the insulator 13 to form the stator divided body 11.

  The stator divided bodies 11 thus created are joined in a predetermined number of rings to form the stator 2, and the rotor 3 is inserted into the stator 2 and incorporated into the housing 4, thereby insulating the stator 2. A highly efficient rotating electrical machine 1 with improved winding space factor while maintaining reliability can be obtained.

  FIG. 7 is a cross-sectional view showing a joined state of the stator divided bodies 11a and 11b adjacent to each other. FIG. 8 shows a cross section AA of FIG. In addition to the first insulation coating 8b, a second insulation coating 14 is provided on the outermost layer electric wire portions 9a, 9b located in the outermost layers of the respective windings 10a, 10b. The respective windings 10a and 10b of the stator divided bodies 11a and 11b adjacent to each other are in different phases, and insulation between the phases is ensured by the second insulating coatings 14 of the stator divided bodies 11a and 11b facing each other. ing. Specifically, each of the second insulation coatings 14 of the stator divided bodies 11a and 11b is configured to cover a surface (interphase side) facing the windings 10a and 10b.

  By disposing the insulating layer in this way, the windings 12a and 12b side of the outermost layer electric wire portions 9a and 9b of the stator divided bodies 11a and 11b, that is, the inner unprocessed electric wire portions 9c have different phases. Even if there is an insulation defect such as a pinhole in the coating of the unprocessed electric wire portion 9c without directly facing the winding 10a or 10b, the withstand voltage between the phases does not decrease. Therefore, in order to maintain the reliability of insulation, it is not necessary to increase the distance between the windings 10a and 10b of the stator divided bodies 11a and 11b adjacent to each other, and it is necessary to increase the covering of the unprocessed electric wire portion 9c. Therefore, the space factor of the winding can be improved accordingly.

  If the second insulating coating 14 is made of a material that can be deformed by an external force, the tension at the time of winding and the stator divided bodies 11a and 11b adjacent to each other when the stator divided bodies 11a and 11b are joined to each other can be obtained. Since the second insulating coating 14 is deformed by the force of pressing each other, the contact surface between the wires constituting the outermost layer electric wire portions 9a, 9b, the contact surface between the outermost layer electric wire portion 9a and the insulator 13, and the outermost layer electric wire portion 9a, 9b. A contact surface between the outer layer electric wire portion 9b and the insulator 13 can be sufficiently secured. As a result, as shown in FIG. 8, it is possible to configure the second insulating coating 14 so as to cover the surfaces on which the windings 10a and 10b face each other without any gaps. And the space factor of the winding can be improved.

  Further, in this embodiment, since insulating paper is not used for insulation between the windings 10a and 10b having different phases, there is no need for an insulating paper insertion process as in the prior art, and the rotating electric machine can be easily fixed. You can assemble a child.

  As described above, in this embodiment, the windings 10a and 10b of the stator divided bodies 11a and 11b adjacent to each other are opposed to each other at the outermost layer electric wire portions 9a and 9b, thereby forming the outermost layer electric wire portions 9a and 9b, respectively. A second insulating coating 14 is formed on the predetermined portion 9aa of the electric wire 9 from above the first insulating coating 8b before winding, and the windings 10a, 10b are opposed to each other by the second insulating coating 14. Since each side is covered, the space factor of the stator winding can be improved while maintaining the reliability of the insulation between the phases, and the effect of realizing the highly efficient rotating electrical machine 1 can be obtained. .

  Further, in the rotating electrical machine 1, a step of forming the second insulating coating 14 on the predetermined portion 9aa of the electric wire 9 having the first insulating coating 8b by powder coating or electrodeposition coating, and the electric wire subjected to the forming processing. 9 is formed by winding a predetermined portion 9aa on the winding groove 12 of the stator piece 7 covered with the insulator 13 so as to cover the outermost layer of the winding 10, and the stator division. Since the stator 11 is manufactured by joining the predetermined number of bodies 11 in a ring shape and the step of inserting and assembling the rotor 3 in the stator 2, the stator is maintained while maintaining the reliability of insulation between the phases. Thus, a highly efficient rotating electrical machine 1 with improved winding space factor can be obtained.

  In this embodiment, powder coating and electrodeposition coating are shown as the method for forming the second insulating coating 14, but spray wiping using electrostatic attraction, fluid dipping, or the like may be used.

  Moreover, in the manufacturing method of the rotating electrical machine in this embodiment, the outermost layer electric wire portion 9a on which the second insulating coating 14 is formed and the untreated electric wire portion 9c having only the first insulating coating 8b are continuously connected. The electric wire 9 is once wound around the winding frame 16, and the step of forming the second insulating coating 14 on the predetermined portion 9aa of the electric wire 9 and the step of forming the electric wire 9 on the winding groove 12 are wound. It goes without saying that the step of winding the wire 9 having been subjected to the forming process around the winding frame 16 can be omitted by continuously performing the step.

Embodiment 2. FIG.
In the first embodiment, the second insulating coating 14 is configured so as to cover the surfaces of the windings 10 on the opposite sides or without any gaps. However, as shown in FIG. By using an insulating material that can be largely deformed by an external force, such as low elastic epoxy, low elastic polyimide, low elastic polyamide, polyester, silicone rubber, urethane or the like having a long linear molecular structure as the insulating coating 14, the adjacent outermost layer You may comprise so that the uneven | corrugated surface of the electric wire 9 used as the outermost layer of the unprocessed electric wire part 9c may be closely_contact | adhered by the 2nd insulation coating 14, while making the electric wire parts 9a and 9b contact | adhere mutually. In this way, by forming the second insulating coating 14 in close contact with the concavity and convexity surfaces of the adjacent wires 9 that are adjacent to each other without any voids, the concave and convex voids between the electric wires 9 that are weak points of insulation are eliminated. Insulation reliability can be further improved.

  In this embodiment, the case where the second insulating coating 14 is formed of an insulating material that can be largely deformed by an external force is shown. However, the electric wire in which the second insulating coating 14 is formed of a semi-cured resin material. 9 is wound around the winding grooves 12a and 12b of the stator pieces 7a and 7b covered with the insulator 13, and the stator divided bodies 11a and 11b adjacent to each other are joined in a predetermined number to form a stator 2. Thereafter, the semi-cured resin material may be finally cured.

Embodiment 3 FIG.
In the first and second embodiments, the second insulating coating 14 is provided on both the outermost layer electric wire portions 9a and 9b of the stator divided bodies 11a and 11b adjacent to each other. However, as shown in FIG. When the insulation performance between the phases can be ensured, the second insulating coating 14 may be provided only on the outermost layer electric wire portion 9a of the one stator divided body 11a. By configuring in this way, it is possible to improve the space factor of one winding.

  In addition, in FIG. 10, although the example which provided the 2nd insulation coating 14 only in the outermost layer electric wire part 9a of the stator division | segmentation body 11a was shown, conversely, it is 2nd only in the outermost layer electric wire part 9b of the stator division | segmentation body 11b. Needless to say, this is the same even if the insulating coating 14 is provided.

  Moreover, in Embodiment 1-3, although the 2nd insulation coating 14 was provided over the perimeter of both or any one of outermost layer electric wire part 9a, 9b, the 2nd insulation coating 14 is provided in the outermost layer electric wire part. 9a, 9b or either one of them is provided only on the surface of the adjacent stator segment 11a or 11b (the surface between the phases) or on the adjacent stator segment 11a or 11b side You may make a surface thicker than the surface on the opposite side (surface by the side of the unprocessed electric wire part 9c). By comprising in this way, the space factor of winding 10a, 10b can be improved further.

  In order to form the second insulation coating 14 having a different thickness in the circumferential direction of the electric wire as described above, for example, to improve the wear resistance on the surface of the first insulating coating 8b of the electric wire 9. Since the lubricant is applied, the lubricant may be removed only on one side, and an insulating layer may be applied to the portion by spray 15 or the like.

Embodiment 4 FIG.
In the first to third embodiments, the stator piece 7 divided in the circumferential direction in pole teeth units and laminated with magnetic steel sheets is covered with the insulator 13, and the second winding groove 12 insulated from the stator piece 7 is formed in the second winding groove 12. The stator divided body 11 was formed by winding the electric wire 9 covering the insulating layer 14, but in this embodiment, as shown in FIG. 12, in the winding grooves 12a and 12b of the adjacent stator pieces 7, After the electric wire 9 having the first insulating coating 8b is wound around the conductor 8a, the second insulating coating 14 is applied to the outermost layer electric wire portions 9a, 9b by powder coating, electrodeposition coating or spraying 15 or the like. Then, the adjacent stator divided bodies 11a and 11b are joined. Other configurations are the same as those in the first embodiment, and thus description thereof is omitted.

  Thus, after the electric wire 9 is wound, the space factor of the winding can be further improved by applying the second insulating coating 14 only to the interphase sides of the outermost layer electric wire portions 9a and 9b facing each other. it can.

  By the way, in FIG. 12, although the case where the 2nd insulation coating 14 was formed in both outermost-layer electric wire parts 9a and 9b was shown, when the insulation performance between phases can be ensured, it may be from either.

  In the first to third embodiments, the insulator 13 having the winding groove 12 is used. However, it goes without saying that the same effect can be obtained even in the structure without the winding groove 12 from the viewpoint of the withstand voltage. There is no.

  DESCRIPTION OF SYMBOLS 1 Rotating electric machine, 2 Stator, 3 Rotor, 4 Housing | casing, 5 Rotating shaft, 6 Bearing, 7, 7a, 7b Stator piece, 8a Conductor, 8b 1st insulation coating, 9 Electric wire, 9a, 9b Outermost layer Electric wire part, 9aa predetermined part, 9c Untreated electric wire part, 10, 10a, 10b Winding, 11, 11a, 11b Stator division, 12, 12a, 12b Winding groove, 13 Insulator, 14 Second insulation coating, 15 Spray, 16 reel.

Claims (8)

A stator piece in which a plurality of stator divided bodies each having a winding formed by winding an electric wire on a stator piece divided in a circumferential direction in pole teeth units and laminated with magnetic steel sheets is annularly joined to each other. In rotating electrical machines ,
Among the above SL plurality of stator divided body, the windings of the stator divided bodies adjacent faces at the respective outermost layers the wire section,
The electric wire has only the first insulating coating for the inner electric wires other than the outermost layer, the outermost layer portion has the first insulating coating, and at least any one of the outermost layer electric wire portions. predetermined portion of the wire or forming the one is provided with a second insulating coating on said first insulating coating,
The rotating electrical machine characterized in that the second insulating coating covers the surface on the opposing side and is in close contact with the opposing uneven surface of an adjacent electric wire without a gap. The rotating electrical machine according to claim 1, wherein a void content of the second insulating coating is 2% or less. The rotating electrical machine according to claim 1, wherein the second insulating coating is formed of an insulating material that can be largely deformed by an external force. The second insulating coating, rotating electrical machine according to claim 1 or 2, characterized in that the insulating material in the resin as a main component is obtained by coating formation on a predetermined portion of the wire.   The step of winding the electric wire having the first insulating coating around the winding groove of the stator piece covered with the insulator, the second insulating coating is powdered on the outermost layer electric wire portion of the electric wire having the first insulating coating. Forming a stator divided body by forming treatment by body coating or electrodeposition coating, forming a stator by joining a predetermined number of the stator divided bodies in an annular shape, and inserting a rotor into the stator A method of manufacturing a rotating electrical machine, comprising a step of assembling.   Forming a second insulating coating by powder coating or electrodeposition coating on a predetermined portion of the electric wire having the first insulating coating; winding of the stator piece covered with the insulator on the formed electric wire; Winding the groove so that the predetermined portion covers the outermost layer of the winding to form a stator divided body, joining a predetermined number of the stator divided bodies in a ring shape, and forming a stator; and A method of manufacturing a rotating electrical machine, comprising the step of inserting and assembling a rotor in the stator. A rotating electrical machine manufactured by the manufacturing method according to claim 5. A rotating electrical machine manufactured by the manufacturing method according to claim 6.

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